Knitted substrate for use in medical bandaging product bandaging product and method of forming the same

ABSTRACT

A medical bandaging product having a predetermined length suitable for a given medical use, including an enclosure formed of a moisture-impervious material sealable to prevent entry of moisture and a medical bandage material positioned therein and sealed against entry of moisture until use. The medical bandage material includes a substrate formed from a single integrated knitted fabric layer having a plurality of interconnected knitted fabric yarns forming a three-dimensional structure. A reactive system is impregnated into or coated onto the substrate. The system remains stable when maintained in substantially moisture-free conditions and hardens upon exposure to sufficient moisture to cooperate with the three-dimensional structure to form a rigid, self supporting structure. A soft, flexible protective wrapping encloses the substrate along its length for providing a cushioning barrier interposed between the substrate and a patient when the medical bandage material is in use.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

[0001] This invention relates generally to the field of orthopedicmedicine and more specifically to the design of an improved medicalbandaging product and material which includes a warp knitted,double-layered fabric substrate, a method for constructing such animproved bandaging product, and a method of constructing and applying anImproved bandaging product.

[0002] Medical bandages for use in the treatment of injuries, such asbroken bones requiring immobilization of a body member, are generallyformed from a strip of fabric or scrim material impregnated with asubstance which hardens into a rigid structure after the strip has beenwrapped around the body member. The hardening substance traditionallyused in carrying out this procedure is plaster-of-paris.

[0003] Conventional practice has been to fabricate a cast or splint uponan Injured limb by initially applying to the limb a protective coveringof a cotton fabric or the like and then overwrapping the covering andlimb with a woven cloth impregnated with plaster-of-paris which has beenwetted by dipping in water immediately prior to application. Thispractice is still in widespread use but possesses several significantdisadvantages. For example, the above-described application procedure ismessy and time consuming. Several components are required andconsiderable skill is necessary.

[0004] In order to alleviate the above-recited disadvantages of theconventional application procedure for plaster-of-paris casts andsplints, unitary splinting materials have been devised and are disclosedin, for example, U.S. Pat. Nos. 3,900,024, 3,923,049, and 4,235,228. Allof these patents describe a padding material with a plurality of layersof plaster-of-paris impregnated cloth. Such unitary splinting materialsare not as messy and can be applied more quickly but still suffer from anumber of disadvantages inherent in plaster-of-paris cast materials. Allplaster-of-paris splints have a relatively low strength to weight ratiowhich results in a finished splint which is very heavy and bulky.Plaster-of-paris splints are slow to harden, requiring 24 to 72 hours toreach maximum strength. Since plaster-of-paris breaks down in water,bathing and showering are difficult Even if wetting due to these causescan be avoided, perspiration over an extended period of time can breakdown the plaster-of-paris and create a significant problem with odor anditching.

[0005] A significant advance in the art of casting and splinting isdisclosed in U.S. Pat. Nos. 4,411,262 and 4,502,479. The castingmaterials disclosed in these patents include bandaging materials whichincorporate a substrate formed from a plurality of flexible fabriclayers, such as fiberglass, impregnated with a moisture-curing resin.These bandaging materials are enclosed in a moisture-free,moisture-impervious package until use. Compared to plaster-of-paris,these products are extremely lightweight, have a very high strength toweight ratio and can be made relatively porous, permitting a flow of airthrough the casting material. However, no provision has been made formoisture-curing systems which incorporate a substrate which is formedfrom a single layer of fabric, yet is strong and absorbent enough to beimpregnated with amounts of moisture-curing resin comparable to thoseamounts absorbed by conventional multi-layered substrates.

[0006] U.S. Pat. Nos. 4,770,299 and 5,003,970, among others owned byapplicant, each disclose roll-form synthetic bandaging products whichinclude the ability to dispense desired lengths of bandaging materialwhen needed, while sealing the remaining length of material for lateruse. Similar products are also sold in precut lengths sealed in a singleuse, moisture-impervious envelope. Although these products have provento be very successful in many applications, each product is formed usingmulti-layered substrate materials.

[0007] Both the conventional plaster-of-paris casting method and themore recent moisture-curable resin casting method possess certaindisadvantages. Plaster-of-paris casts are bulky, heavy and difficult toapply. Even though moisture-curable resin bandage products arelightweight, durable and relatively easy to apply, such products remainrelatively expensive to produce.

[0008] This invention combines the advantages of both plaster-of-parisand moisture-curable resin systems while avoiding their respectivedisadvantages. This is accomplished by providing a unitary splintingsystem which incorporates moisture-curable resin materials formed from aresin-impregnated substrate having both a lighter weight and improvedstrength. Unlike prior art resin systems which employ multiple layers ofresin-impregnated substrate layers, the resin system of the presentinvention takes advantage of a single layer of warp-knitted fabric. Thisunique substrate fabric employs a continuous inlaid stitch. This resultsin a double-knitted fabric which has a lighter weight, yet retains theabsorption capabilities of multi-layered substrates. Using a singlelayer of double-knitted fabric in the substrate further results inreduced production and labor costs in comparison with other syntheticcast products. For example, assembly of prior art, multi-layeredsubstrates requires placement of the overlying fabric layers of thesubstrate by hand, which is a time consuming process. To ensure that thefabric layers do not separate, the layers must then be stitched togetherby running one or more seams along the entire length of the substrate.Use of a substrate having only one layer eliminates theselabor-intensive layering and stitching steps, and results in a bandagingproduct which is more cost effective to produce.

[0009] Eliminating the multi-layered substrate structure also eliminatesthe rough, uneven edges present on prior art cured substrates. Suchfrayed edges are commonplace in prior art bandaging products havingmulti-layered substrates, and materialize after the resin in suchsubstrates undergoes final curing. These rough edges cause irritationand damage to the skin of the patient upon whom the bandage isultimately applied. In contrast, the substrate of the present inventionhas uniform side edges which result from using the single-layer ofdouble-knitted fabric, rather than multiple, uneven fabric layers. Thisnovel structure results in a medical bandage product having amoisture-curable substrate which is lighter in weight than conventionalproducts, yet is stronger and more cost-effective to produce.

SUMMARY OF THE INVENTION

[0010] It is therefore an object of the invention to provide a medicalbandaging product having a medical material that includes a substrateformed from a single layer of double-knitted fabric capable of absorbingan increased amount of a moisture-curable resin which hardens thebandaging material upon exposure to moisture to form a rigid,self-supporting structure.

[0011] It is another object of the invention to provide a medicalbandaging product including a medical bandaging material formed from aresin-impregnated substrate having a knitted structure that providesenhanced strength to the bandaging material after the resin is curedwithout compromising flexibility of the material prior to curing.

[0012] It is another object of the invention to provide a medicalbandage material which can be dispensed in any desired length whilepreventing hardening of the remaining material until use of theremaining material is desired.

[0013] It is another object of the invention to provide a medicalbandage material having a medical material that includes aresin-impregnated substrate possessing a relatively high strength toweight ratio resulting in a finished splint which is lighter and lessbulky than splints using conventional plaster-of-paris ormoisture-curable resin systems.

[0014] It is another object of the invention to provide a medicalbandaging product having a medical bandage material which incorporates asubstrate formed from a single layer of double-knitted fabric, therebyeliminating the formation of rough, uneven side edges which commonlyform on conventional multi-layered, moisture curable substrates afterthe curing process is complete.

[0015] It is another object of the invention to provide a medicalbandaging product which can be manufactured and sold in pre-cut lengths,each of which is sealed within a moisture-impervious package to preventhardening of the product until use is desired.

[0016] It is another object of the invention to provide a medicalbandaging product which is less labor-intensive, and thus more costeffective, to produce than conventional bandaging products thatincorporate multi-layered substrates.

[0017] These and other objects and advantages of the present inventionare achieved in the preferred embodiment disclosed below by providing amedical bandaging product having a predetermined length suitable for agiven medical use. The medical bandaging product includes an enclosureformed of a moisture-impervious material sealable to prevent entry ofmoisture. A medical bandage material is positioned in the enclosure andsealed therein against entry of moisture until use. The medical bandagematerial includes a substrate formed from a single integrated knittedfabric layer having a plurality of interconnected knitted fabric forminga three-dimensional structure. A reactive system is impregnated into orcoated onto the substrate. The reactive system remains stable whenmaintained in substantially moisture-free conditions and hardens uponexposure to sufficient moisture to cooperate with the three-dimensionalstructure to form a rigid, self supporting structure. A soft, flexibleprotective wrapping encloses the substrate along its length forproviding a cushioning barrier interposed between the substrate and apatient when the medical bandage material is in use.

[0018] According to one preferred embodiment of the invention, themoisture-impervious material is an aluminum foil laminate having anouter tear resistant layer, a central aluminum foil layer and an innerheat sealable plastic layer.

[0019] According to another preferred embodiment of the invention, theprotective wrapping enclosing the substrate is a fibrous non-wovenmaterial.

[0020] According to yet another preferred embodiment of the invention,the protective wrapping enclosing the substrate is a non-wovenpolypropylene sheet folded along its longitudinal axis to define anenvelope within which the substrate is positioned.

[0021] According to yet another embodiment of the invention, thereactive system is synthesized from a blended polyisocyanate, polyol,catalyst and stabilizer.

[0022] According to yet another preferred embodiment of the invention, amedical bandaging product is provided in roll form for being dispensedin predetermined lengths suitable for a given medical use. The medicalbandaging product includes an elongate sleeve formed ofmoisture-impervious material and sealable to prevent entry of moisture.An elongate medical bandage material substantially the same length asthe sleeve is positioned in the sleeve in a single length along thelength of the sleeve and sealed therein against entry of moisture untiluse. The medical bandage material includes a substrate formed from asingle integrated knitted fabric sheet having plurality ofinterconnected knitted fabric layers forming a three-dimensionalstructure. A reactive system is impregnated into or coated onto thesubstrate. The reactive system remains stable when maintained insubstantially moisture-free conditions and hardens upon exposure tosufficient moisture to cooperate with the three-dimensional structure toform a rigid, self-supporting structure. A soft, flexible protectivewrapping encloses the substrate along its length for providing acushioning barrier interposed between the substrate and a patient whenthe medical bandage material is in use. The medical bandage material ispositioned in the enclosure for being dispensed in a desired use lengthfrom the sleeve, and the sleeve is adapted for being resealed to preventmoisture from entering the enclosure.

[0023] According to yet another preferred embodiment of the invention,the medical bandaging product includes resealing means for resealing thesleeve against entry of moisture after a predetermined length of thebandaging product has been dispensed for use to prevent hardening of thesubstrate remaining in the sleeve.

[0024] According to yet another preferred embodiment of the invention,the resealing means for resealing the sleeve is selected from a groupwhich includes tape, a clamp, and a clip for holding a folded end of thesleeve closed.

[0025] According to yet another preferred embodiment of the invention,the sleeve and the medical bandage material positioned therein areformed into a coil, thereby creating the roll form of the medicalbandaging product.

[0026] According to yet another preferred embodiment of the invention,the medical bandaging product includes a dispenser within which the coilis contained.

[0027] According to yet another preferred embodiment of the invention,the dispenser includes a container within which the coil is positioned.The container defines a slot therein in which a leading end of the coilmay be positioned and through which the sleeve and the medical bandagepositioned therein are dispensed as needed.

[0028] An embodiment of the method of constructing a medical bandagingproduct according to the invention includes the step of providing anelongate, moisture-impervious sleeve and an elongate medical bandagematerial formed from a substrate enclosed within a protective wrapping.The substrate is formed from a single integrated knitted fabric sheethaving a plurality of interconnected fabric layers forming athree-dimensional structure. The method further includes the step ofimpregnating into or coating onto the substrate a reactive system whichremains stable when maintained in substantially moisture-free conditionsand hardens upon exposure to sufficient moisture to cooperate with-thethree-dimensional structure form a rigid, self-supporting structure. Alength of the elongate medical bandaging material is then positionedwithin the elongate sleeve. The elongate medical bandage material hasgenerally the same length as the sleeve and extends along the length ofthe sleeve in a single layer. The sleeve is then sealed to prevent entryof moisture therein until use.

[0029] According to one preferred embodiment of the invention, themethod includes the step of providing a moisture impervious sleeve and asubstrate for being enclosed within a protective wrapping. The substrateis formed from a single integrated knitted fabric sheet having aplurality of overlaid knitted fabric yarns forming a three-dimensionalstructure. The method further includes the step of impregnating into orcoating onto the substrate a reactive system which remains stable whenmaintained in substantially moisture-free conditions and hardens uponexposure to sufficient moisture to cooperate with the three-dimensionalstructure to form a rigid, self-supporting structure. The coated orimpregnated substrate is then positioned within the protective wrappingto form a medical bandage material. A length of the medical bandagematerial having generally the same length as the sleeve is thenpositioned within the sleeve and extends along the length of the sleevein a single layer. The sleeve is then sealed to prevent entry ofmoisture until use.

[0030] According to another preferred embodiment of the invention, themethod includes the step of resealing the sleeve against entry ofmoisture after a predetermined length of the bandaging material has beendispensed for use to prevent hardening of the substrate remaining in thesleeve.

[0031] According to yet another preferred embodiment of the invention,the method further includes the step of rolling the sleeve with themedical bandage material therein into a coil.

[0032] According to yet another preferred embodiment of the invention,the method further includes the step of packaging the coil in adispenser.

[0033] According to yet another preferred embodiment of the invention,the dispenser provided is a box having with a slot therein for feeding adesired length of the medical bandaging material therethrough.

[0034] A further embodiment of the method according to the invention isa method of utilizing a medical bandaging product. The method includesthe step of providing an enclosure and amedical bandage material. Themedical bandage material includes a substrate enclosed within aprotective wrapping. The substrate includes a single integrated knittedfabric sheet having a plurality of overlaid fabric layers forming athree-dimensional structure. A reactive system is impregnated into orcoating onto the substrate. The reactive system remains stable whenmaintained in substantially moisture-free conditions and hardens uponexposure to sufficient moisture to cooperate with the three-dimensionalstructure to form a rigid, self-supporting structure. The method furtherincludes the steps of positioning the elongate medical bandage materialwithin the elongate sleeve, sealing the sleeve to prevent entry ofmoisture until use, removing the medical bandage material from thesleeve immediately prior to use, wetting the substrate to activate thereactive system; and applying the medical bandaging material to apatient.

[0035] According to one preferred embodiment of the method of utilizingthe medical bandaging product includes the step of overwrapping themedical bandaging material with an elastic bandage to maintain themedical bandaging material in close conformity with the patient duringcuring of the moisture-curable resin.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Some of the objects of the invention have been set forth above.Other objects and advantages of the invention will appear as thedescription of the invention proceeds when taken in conjunction with thefollowing drawings, in which:

[0037]FIG. 1 is a perspective view of a medical bandaging productaccording to one preferred embodiment of the invention;

[0038]FIG. 2 is a cut-away fragmentary perspective view of the medicalbandaging product shown in FIG. 1;

[0039]FIG. 3 is a cross-sectional view taken along lines 3-3 of FIG. 1;

[0040]FIG. 4 is a perspective view of a medical bandaging productaccording to another preferred embodiment of the invention;

[0041]FIG. 5 is a cut-away perspective view of a length of medicalbandage material according to FIG. 4;

[0042]FIG. 6 is a cross-sectional view taken along Lines 6-6 of FIG. 5;

[0043]FIG. 7 is a stitch diagram showing the stitch pattern used to formthe substrate according to the present invention;

[0044]FIG. 8 is a photograph of an example of the substrate formedaccording to the present invention showing the front or top face of thesubstrate;

[0045]FIG. 9 is a photograph of the substrate according to the presentinvention showing the back or bottom face of the substrate;

[0046]FIG. 10 is a perspective view of a medical bandaging productaccording to an alternative embodiment of the invention

[0047]FIG. 11 is a vertical cross section of the medical bandagingproduct shown in FIG. 10;

[0048]FIG. 12 is a perspective view of the medical bandaging productshown in FIG. 10 in a dispensing box, and showing a preferred embodimentof resealing the dispensing sleeve;

[0049]FIG. 13 is a fragmentary perspective view of one embodiment of themedical bandaging product with a zip end closure;

[0050]FIG. 14 is a perspective view of the medical bandaging productaccording to FIG. 13 showing an alternative preferred embodiment ofresealing the medical bandaging product; and

[0051]FIGS. 15 through 19 illustrate a preferred manner of preparing andapplying the medical bandage material according to the presentinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

[0052] Referring now specifically to the drawings, a medical bandagingproduct according to-the present invention is shown generally in FIG. 1at reference numeral 10. The medical bandaging product 10 includes amoisture-impervious package 11 formed from two laminated sheets 12, 13which are placed in registration and heat sealed along opposite edges 14and 15. As is shown in FIGS. 2 and 3, the bandaging product 10 alsoincludes a medical bandage 20 which is maintained in moisture-freeconditions within the package 11 until use. The bandage 20 includes asubstrate 21 which is encased within an outer cover 22 formed of a soft,flexible. non-woven fiber such as polypropylene or any other suitablehydrophobic fiber. Enclosing the substrate 21 within the cover 22provides a cushioning protective layer between the skin of a patient andthe substrate 21 after the bandage 20 has been applied. As discussedmore fully in reference to FIGS. 8 through 12 below, the substrate 21 isformed from a single layer of a knitted, relatively open, fabric, suchas fiberglass.

[0053] The package 11 includes outer, middle, and inner layers. Theouter layer is preferably formed of a tear-resistant plastic film. Themiddle layer is preferably formed from aluminum foil and acts as amoisture resistant barrier for protecting the bandage 20 while storedwithin the package 11. The inner layer is preferably formed from aplastic film having thermoplastic properties suitable for heat-sealingthe interior of the package 11 securely against moisture.

[0054] Referring now to FIG. 4, a medical bandaging product according toanother preferred embodiment of the invention is illustrated and showngenerally at reference numeral 30. Bandaging product 30 may be sold inany convenient length, such as 24 feet, and is rolled into a coil andpositioned within a suitable dispenser 31. Dispenser 31 is provided witha slot 32 defined in one lower corner through which an end 33 ofbandaging product 30 extends for dispensing the product 30 from thedispenser 31 in the direction “D” shown.

[0055] Referring now to FIG. 6, the bandaging product 30 includes anelongate medical bandaging material 35 which is packaged inmoisture-free conditions in a foil sleeve 36. The sleeve 36 is formedfrom two laminated, elongate foil sheets 36A, 36B, which are placed inregistration and heat sealed along opposing side edges 37A, 37B to forma tube having an open end 38. Each sheet 36A and 36B is formed from thesame materials and includes the same components as the package 11. Thebandage material 35 includes a substrate 39, which is shown in FIGS. 5and 6 surrounded by a tubular wrapping 40 formed of the same material asthe cover 12 described above in reference to FIG. 3. Enclosing thesubstrate 39 within the wrapping 40 protects and cushions the skin of apatient from the substrate 39 after the bandage material 35 has beenapplied. As discussed more fully in reference to FIGS. 7 through 9below, the substrate 39 is formed from a single layer of a knittedrelatively open fabric, such as fiberglass which is identical to thatused to form substrate 21. The substrate 21 or 39 may alternatively beformed from polyester or polypropylene.

[0056] Referring now to FIGS. 7 through 9, the preferred structure ofthe fabric used to form substrate 21 and substrate 39 is shown. Thesubstrate of the present invention is preferably knitted on a warpknitting machine employing three guide bars. These guide bars are shownin the stitch diagram illustrated in FIG. 7 as the front, middle andback guide bars, respectively. Using substrate 21 as a representativeexample FIG. 7 shows the preferred stitch pattern used to form thesubstrate 21. Three yarns 21A, 21B, and 21C are employed. Yarn 21A isthreaded on the front guide bar and has back-and-forth movement tonon-adjacent needles in successive courses as indicated by the numbers(0-2/2-4). Yarns 21B and 21C are threaded on the respective middle andback guide bars and have similar movements as indicated by the numbers(0-0/4-4/8-8/4-4) and (68/0-2) respectively.

[0057] Yams 21A, 21B, and 21C are knitted on the respective front,middle and back guide bars continuously, resulting in athree-dimensional fabric having sufficient weight to absorb adequatequantities of resin. Although any number of courses per inch may beused, a preferred number is 8 courses per inch, or 31.49 courses per 10centimeters, with a preferred range of between 4 to 30 courses per inch,or 31.49 to 47.24 courses per 10 centimeters. A preferred number ofwales is 10 per inch, or 39.37 per 10 centimeters, with a preferredrange of between 6 to 12 wales per inch, or 23.62 to 47.24 wales per 10centimeters. FIGS. 8 and 9 show photographs of the respective upper andlower surfaces of the substrate upon completion of the knitting processillustrated in FIG. 7.

[0058] The preferred substrate material used to form yarns 21A, 21B and21C is the fiberglass material used by applicant in its ORTHOGLASSpadded splint material. Specifically, each yarn 21A, 21B and 21C ispreferably a yarn knitted from a textured multifilament EC9 glass yarnof 140Tex, with a preferred range of between 68Tex to 156Tex, and a flatmultifilament EC9 glass yarn of 136Tex, with a preferred range ofbetween 68Tex to 156Tex. Any suitable widths of fabric may beconstructed, but conventional widths are presently 2.5 cm to 15.0 cm, in2.5 cm increments. The finished weight of the fabric is preferably 1,750g/m², with a preferred range of between 800 g/m² to 3,000 g/m². Thefinished thickness of the fabric is preferably 5.0 mm, with a preferredrange of between 2.0 mm to 10.0 mm.

[0059] Other materials which may be suitable for forming the fabric usedin substrate 21 or 39 include materials formed from a composition ofaluminum oxide, silicone oxide and boron oxide and sold under the nameNEXTEL 440 by Thermostatic Industries, Inc.

[0060] Substrates 21 and 39 are each impregnated or coated with areactive system which remains stable when maintained in substantiallymoisture-free conditions blat which hardens upon exposure to sufficientmoisture to form a rigid, self-supporting structure. A typicalformulation of the reaction system is set forth in the following table:

[0061] Typical Formulation: Isonateι 143L or polyisocyanate 50.0%Mondurι CD or Rubinateι XI168 Pluracolι P1010 polyol 46.6% DC-200Silicone defoaming agent 0.30% Benzoyl Chloride stabilizer 0.10%Thancatι DM-70 catalyst  3.0%  100%

[0062] A complete discussion of the parameters of the reactive system,the manner of production and the variables which apply are found in U.S.Pat. No. 4,411,262, referred to above. The weight of substrate 21 or 39after being impregnated with the reactive system is preferably 3,144g/m, with a preferred range of between 2,490 g/m to 4,534 g/m. Afterundergoing the curing process, the finished weight of the impregnatedsubstrate 21 or 39 is preferably 3,168 g/m, with a preferred range ofbetween 3,000 g/m to 4,600 g/m.

[0063] Referring now to FIGS. 10 and 11, an alternative medicalbandaging product is illustrated and shown generally at referencenumeral 60. The bandaging product 60 includes a moisture-impervious foilbag 61 within which is contained a desired length of coiled medicalbandaging material 70. Coiled bandaging material 70 includes the samecomponents and is formed from the same materials as bandaging material25. The foil bag 61 is constructed from the same laminated foil materialused to form the pouch 11 and sleeve 36 described above. As is shown inFIG. 11, the bag 61 includes an enlarged enclosure 64 within which themedical bandaging material 70 is contained, and an elongate dispensingsleeve 66. Referring again to FIG. 10, dispensing sleeve 66 defines anopen end 67 through which an end 71 of the medical bandaging material 70is extended for dispensing. The bag 61 should relatively snugly surroundthe medical bandaging material 70 to retard entry of moisture into thebag 61 as the material 70 is being dispensed through the open end 67.The open end 67 of sleeve 68 is sealed with sealing means such as aclamp 75.

[0064] Referring now to FIG. 12, the bandaging product 60 is shownpositioned within a suitable dispenser 80. Dispenser 80 is identical tothe dispenser 31 described above in reference to FIG. 4, and includes aslot 82 defined in one lower corner through which the end 67 of sleeve66 of the bandaging product 60 extends.

[0065] Referring now to FIGS. 13 and 14, alternative sealing means whichmaybe used to seal the end 67 of the sleeve 66 include but are notlimited to a zip-type closure 76 as shown in FIG. 13, or a tape strip 77such as that shown in FIG. 14. The clamp 75, zip-type closure 76 andtape strip 77 may also be used to close the open end 38 of the sleeve 36of the bandaging product 30 described above with reference to FIG. 5.

[0066] Other types of sealing mechanisms may also be employed to closethe sleeves 36 and 66 such as, for example, a clip for holding a foldedend of the sleeve 36 or 66 closed. A soft, conformable gasketing devicemay alternatively be used. Such a gasketing device would include springloaded compression, leverage clamping or screw action of sufficientstrength to prevent entry of moisture into sleeve 36 or 66. Anothersuitable device for sealing the sleeve 36 or 66 is a pair of springloaded rollers. Such rollers roll backwards slightly when compressed,which would in turn push medical bandage material 35 and 70 backslightly into respective sleeves 36 and 66, thereby forming a betterseal. Another alternative sealing means is one which pushes the medicalbandage material 35 and 70 back into respective sleeves 36 and 66 asufficient distance (approximately one inch), so that the open ends 37and 67 may be heat sealed.

[0067] Referring now to FIGS. 15 through 19, preparation and applicationof the medical bandaging material of the present invention isillustrated. Using medical bandage material 35 as a representativeexample, as is shown in FIG. 15 the medical bandaging material 35 isfirst measured and cut to length using scissors or a knife. Once theappropriate length of material 35 is been cut, the sleeve 36 must beimmediately resealed to prevent moisture intrusion which can harden theremaining material. See FIGS. 12 and 13.

[0068] Referring now to FIG. 16, moisture curing of the resin isactivated by immersing the medical bandage material 35 in water. Thecuring process may alternatively be activated by spraying the bandagematerial 35 with water. Excess moisture is then removed from thematerial 35 by either squeezing the material 35 or rolling the material35 in an absorbent towel. As is shown in FIG. 17, the moisture-curingprocess can alternatively take place over a longer period of time byexposing the reactive system impregnated within or coated on thesubstrate to atmospheric moisture.

[0069] Referring now to FIGS. 18 and 19, the splint shown is commonlyknown as a posterior short leg splint, and is formed by molding a lengthof the medical bandage 35 along the calf, over the Achille's tendon andheel, and onto the foot. As is shown in FIG. 18, an appropriate lengthof moistened medical bandage material 35 is first formed to the shape ofa body member to be immobilized. Once the bandage 35 is formed to theshape of the body member, the bandage 35 is overwrapped with aconventional elastic bandage “B”, as is shown in FIG. 19.

[0070] Although the medical bandage material 35 of medical bandageproduct 30 is shown in FIGS. 18 and 19 in use as a posterior short legsplint, the medical bandage products 10, 30 and 60 may be utilized inany suitable medical procedure where immobilization of one or more bodymembers is required.

[0071] A medical bandaging product and material formed of amoisture-curable plastic material, a method for constructing such animproved medical bandage, and a method of constructing and applying animproved bandaging product is described above. Various details of theinvention may be changed without departing from its scope. Furthermore,the foregoing description of the preferred embodiment of the inventionand the best mode for practicing the invention are provided for thepurpose of illustration only and not for the purpose of limitation—theinvention being defined by the claims.

[0072] The reader's attention is directed to all papers and documentswhich are filed concurrently with or previous to this specification inconnection with this application and which are open to public inspectionwith this specification, and the contents of all such papers anddocuments are incorporated herein by reference.

[0073] All of the features disclosed in this specification (includingany accompanying claims, abstract and drawings), and/or all of the stepsof any method or process so disclosed, may be combined in anycombination, except combinations where at least some of such featuresand/or steps are mutually exclusive.

[0074] Each feature disclosed in this specification (including anyaccompanying claims, abstract and drawings), may be replaced byalternative features serving the same, equivalent or similar purpose,unless expressly stated otherwise. Thus, unless expressly statedotherwise, each feature disclosed is one example only of a genericseries of equivalent or similar features.

[0075] The invention is not restricted to the details of the foregoingembodiment(s). The invention extend to any novel one, or any novelcombination, of the features disclosed in this specification (includingany accompanying claims, abstract and drawings), or to any novel one, orany novel combination, of the steps of any method or process sodisclosed.

1. A medical bandaging product comprising: (a) an enclosure formed of amoisture-impervious material sealable to prevent entry of moisture; and(b) a medical bandage material position in said enclosure and sealedtherein against entry of moisture until use, said medical bandagematerial comprising: (i) a substrate comprising a single integratedknitted fabric layer having a plurality of interconnected knitted fabricyarns forming a three-dimensional structure; (ii) a reactive systemimpregnated into or coated onto said substrate, said system remainingstable when maintained in substantially moisture-free conditions andhardening upon exposure to sufficient moisture to cooperate with saidthree-dimensional structure to form a rigid, self supporting structure;and (iii) a soft, flexible protective wrapping enclosing the substratealong its length for providing a cushioning barrier interposed betweenthe substrate and a patient when said medical bandage material is inuse.
 2. A medical bandaging product according to claim 2, wherein saidmoisture-impervious material comprises an aluminum foil laminate havingan outer tear resistant layer, a central aluminum foil layer and aninner heat sealable plastic layer.
 3. A medical bandaging productaccording to claim 1 or 2, wherein said protective wrapping enclosingthe substrate comprises a fibrous nonwoven material.
 4. A medicalbandaging product according to claim 1, 2 or 3, wherein said protectivewrapping enclosing the substrate comprises a nonwoven polypropylenesheet folded along its longitudinal axis to define an envelope withinwhich the substrate is positioned.
 5. A medical bandaging productaccording to any proceeding claim 1, wherein said reactive systemcomprises a blended polyisocyanate, polyol, catalyst and stabilizer. 6.A medical bandaging product as claimed in any proceeding claim 1 in rollform for being dispensed in suitable lengths for a given medical use, inwhich: (a) the enclosure comprises an elongate sleeve; (b) the medicalbandage material is of substantially the same length as the sleeve in asingle length along the length of the sleeve, The medical bandagematerial being positioned in the enclosure for being dispensed indesired use length from said sleeve, the sleeve being adapted for beingresealed to prevent moisture from entering the enclosure.
 7. A medicalbandaging product according to claim 6, wherein said resealing means forresealing the sleeve is selected from the group consisting of tape, aclamp, and a clip for holding a folded end of the sleeve closed.
 8. Amedical bandaging product according to claim 6 or 7, wherein said sleeveand the medical bandage material positioned therein are formed into acoil, thereby creating the roll form of the medical bandaging product.9. A medical bandaging product according to claim 6, 7 or 8, andincluding a dispenser within which said roll or coil is containedcontaminated.
 10. A medical bandaging product according to claim 9,wherein said dispenser comprises a container within which the roll orcoil is positioned, said container defining a slot therein in which aleading end of the coil may be positioned and through which the sleeveand the medical bandage positioned therein are dispensed as needed. 11.A method of constructing a medical bandaging product, comprising thesteps of: (a) providing a moisture-impervious sleeve and a medicalbandage material comprised of a substrate enclosed within a protectivewrapping, said substrate comprising a single integrated knitted fabricsheet having a plurality of interconnected fabric yarns forming athree-dimensional structure; (b) impregnating into or coating onto thesubstrate a reactive system which remains stable when maintained insubstantially moisture-free conditions and hardens upon exposure tosufficient moisture to cooperate with said three-dimensional structureto form a rigid, self-supporting structure; (c) positioning within saidelongate sleeve a length of said elongate medical bandage materialhaving generally the same length as the sleeve and extending along thelength of the sleeve in a single layer; and (d) sealing the sleeve toprevent entry of moisture therein until use.
 12. A method ofconstructing a medical bandaging product as claimed in claim 11,comprising providing an elongate sleeve and an elongate medical bandagematerial.
 13. A method of constructing a medical bandaging productaccording to claim 11 or 12, and including the step of resealing thesleeve against entry of moisture after a predetermined length of thebandaging material has been dispensed for use to prevent hardening ofthe substrate remaining in the sleeve.
 14. A method of constructing amedical bandaging product according to claim 11, 12, or 13, andincluding the step of rolling the sleeve with the medical bandagematerial therein into a coil.
 15. A method of constructing a medicalbandaging product according to claim 14, and including the step ofpackaging said coil in a dispenser.
 16. A method of constructing amedical bandaging product according to claim 15, wherein said dispensercomprises a box provided with a slot therein for feeding a desiredlength of the medical bandaging material therethrough.
 17. A method ofutilizing a medical bandaging product, comprising the steps of: (a)providing an enclosure and a medical bandage material comprised of asubstrate enclosed within a protective wrapping, said substratecomprising a single integrated knitted fabric sheet having a pluralityof interconnected fabric yarns forming a three-dimensional structure;(b) impregnating into or coating onto said substrate a reactive systemwhich remains stable when maintained in substantially moisture-freeconditions and hardens upon exposure to sufficient moisture to cooperatewith said three-dimensional structure to form a rigid, self-supportingstructure; (c) positioning the medical bandage material within saidelongate sleeve; (d) sealing the sleeve to prevent entry of moistureuntil use; [[:]] (e) removing the medical bandage material from thesleeve immediately prior to use; (f) wetting the substrate to activatethe reactive system; and (g) applying the medical bandaging material toa patient.
 18. A method according to claim 17, and including the step ofoverwrapping the medical bandaging material with an elastic bandage tomaintain the medical bandaging material in close conformity with thepatient during the curing of the moisture-curable resin.
 19. A medicalbandaging product having a predetermined length suitable for a givenmedical use, comprising: (a) an enclosure formed of amoisture-impervious material sealable to prevent entry of moisture; and(b) a medical bandage material positioned in said enclosure and sealedtherein against entry of moisture until use, said medical bandagematerial comprising: (i) a substrate comprising a single integratedknitted fabric layer having a plurality of interconnected knitted fabricyarns forming a three-dimensional structure; (ii) a reactive systemimpregnated into or coated onto said substrate, said system remainingstable when maintained in substantially moisture-free conditions andhardening upon exposure to sufficient moisture to cooperate with saidthree-dimensional structure to form a rigid, self supporting structure;and (iii) a soft, flexible protective wrapping enclosing the substratealong its length for providing a cushioning barrier interposed betweenthe substrate and a patient when said medical bandage material is inuse.
 20. A medical bandaging product in roll form for being dispensed inpredetermined lengths suitable for a given medical use, comprising: (a)an elongate sleeve formed of moisture-impervious material and sealableto prevent entry of moisture; (b) an elongate medical bandage materialsubstantially the same length as the sleeve and positioned in saidsleeve in a single length along the length of the sleeve and sealedtherein against entry of moisture until use, said medical bandagematerial comprising: (I) a substrate comprising a single integratedknitted fabric sheet having a plurality of interconnected knitted fabricyarns forming a three-dimensional structure; (ii) a reactive systemimpregnated into or coated onto said substrate, said system remainingstable when maintained in substantially moisture-free conditions andhardening upon exposure to sufficient moisture to cooperate with saidthree-dimensional structure to form a rigid, self-supporting structure;and (iii) a soft, flexible protective wrapping enclosing the substratealong its length for providing a cushioning barrier interposed betweenthe substrate and a patient when said medical bandage material is inuse; the medical bandage material being positioned in the enclosure forbeing dispensed in a desired use length from said sleeve, the sleeveadapted for being resealed to prevent moisture from entering theenclosure.
 21. A method of constructing a medical bandaging product,comprising the steps of: (a) providing an elongate, moisture-impervioussleeve and an elongate medical bandage material comprised of a substrateenclosed within a protective wrapping, said substrate comprising asingle integrated knitted fabric sheet having a plurality ofinterconnected fabric yarns forming a three-dimensional structure; (b)impregnating into or coating onto the substrate a reactive system whichremains stable when maintained in substantially moisture-free conditionsand hardens upon exposure to sufficient moisture to cooperate with saidthree-dimensional structure to form a rigid, self-supporting structure;(c) positioning within said elongate sleeve a length of said elongatemedical bandage material having generally the same length as the sleeveand extending along the length of the sleeve in a single layer; and (d)sealing the sleeve to prevent entry of moisture therein until use.
 22. Amethod of constructing a medical bandaging product, comprising the stepsof: (a) providing a moisture impervious sleeve and a substrate for beingenclosed within a protective wrapping, said substrate comprising asingle integrated knitted fabric sheet having a plurality ofinterconnected knitted fabric yarns forming a three-dimensionalstructure; (b) impregnating into or coating onto said substrate areactive system which remains stable when maintained in substantiallymoisture-free conditions and hardens upon exposure to sufficientmoisture to cooperate with said three-dimensional structure to form arigid, self-supporting structure; (c) positioning the coated orimpregnated substrate within the protective wrapping to form a medicalbandage material; (d) positioning within the sleeve a length of saidmedical bandage material having generally the same length as the sleeveand extending along the length of the sleeve in a single layer; and (e)sealing the sleeve to prevent entry of moisture until use.
 23. A methodof utilizing a medical bandaging product, comprising the steps of: (a)providing an enclosure and a medical bandage material comprised of asubstrate enclosed within a protective wrapping, said substratecomprising a single integrated knitted fabric sheet having a pluralityof interconnected fabric yarns forming a three-dimensional structure;(b) impregnating into or coating onto said substrate a reactive systemwhich remains stable when maintained in substantially moisture-freeconditions and hardens upon exposure to sufficient moisture to cooperatewith said three-dimensional structure to form a rigid, self-supportingstructure; (c) positioning the elongate medical bandage material withinsaid elongate sleeve; (d) (e) sealing the sleeve to prevent entry ofmoisture until use; (e) (f) removing the medical bandage material fromthe sleeve immediately prior to use; (f) (g) wetting the substrate toactivate the reactive system; and (g) (h) applying the medical bandagingmaterial to a patient.